Analysis and Control of Gear Rattle Noise for E-Axle 2023-01-7019

As the main power form of new energy vehicles, e-axle systems are has been widely used in passenger vehicles and commercial vehicles. A passenger car equipped with an e-axle, in constant speed and low torque conditions, there is a noticeable rattle noise, through experimental investigation and comparative analysis, it is confirmed that the connection spline of motor and reducer is the main influencing factor. Then, Through the qualitative analysis of simulation, it is found that both spline clearance and misalignment have an amplification effect on the motor speed, thereby stimulating the gear pair of the reducer to produce rattle. The amplification effect of spline clearance is stronger than that of spline misalignment. Therefore, improving the stiffness and application amount of lubricating grease while controlling the spline sample to meet the design requirements can effectively solve the problem of rattle, improve the accuracy of spline alignment, and significantly reduce the probability of rattle. An engineering solution has been proposed for the problem of gear rattle in e-axle, effectively improving the NVH level of similar e-axle products.